Fiber blends for garments with high thermal, abrasion resistance, and moisture management properties

ABSTRACT

Fiber blends useful for garments with a balance of high thermal, abrasion resistance, and moisture management properties are disclosed. The fiber blends comprise a hydrophobic fiber component, a hydrophilic fiber component, a structural fiber component, and an optional antistatic fiber. Yarns, fabrics, and garments comprising the fiber blends are also disclosed. Such garments are particularly useful for occupations requiring high thermal properties and abrasion resistance, such as fire fighters, utility workers, and military personnel, without compromising comfort of the wearers by maintaining breathability and moisture management properties of the fabric.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national phase patent application under 35U.S.C. 371 of International Patent Application No. PCT/US2011/034265entitled “Fiber Blends for Garments with High Thermal, AbrasionResistance, and Moisture Management Properties” filed Apr. 28, 2011,which claims benefit of priority under PCT Article 8 of U.S. ProvisionalApplication No. 61/329,876 filed Apr. 30, 2010, each of which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to fiber blends. Moreparticularly, the invention relates to fiber blends used for a balanceof high thermal, abrasion resistance, and moisture management propertiesand to the yarns, fabrics, and garments made from the fiber blends.

BACKGROUND OF THE INVENTION

Flame-resistant fabrics (also variously referred to as “fire-resistant,”“flame-retardant,” and “fire-retardant” fabrics) are fabrics that, onceignited, tend not to sustain a flame when the source of ignition isremoved. Considerable research has been directed toward the developmentand improvement of flame-resistant fabrics for use in various products,including clothing and bedding. Flame-resistant clothing is often wornby workers involved in activities such as industrial manufacturing andprocessing (such as oil, gas, and steel industries), fire-fighting,electrical utility work, military work, and other endeavors that entaila significant risk of being exposed to open flame, flash fire, momentaryelectrical arcs, and/or molten metal splash. Non-flame resistant workclothes can ignite and will continue to burn even after the source ofignition has been removed. Untreated natural fabrics will continue toburn until the fabric is totally consumed and non-flame resistantsynthetic fabrics will burn with melting and dripping causing severecontact burns to the skin. the majority of severe and fatal burninjuries are due to the individual's clothing igniting and continuing toburn, not by the exposure itself. The abrasion resistance of protectivefabrics is also an important performance property, as garments whichdevelop failures, such as holes and rips, can compromise the protectiveproperties of the fabric.

Flame-resistant fabrics include both fabrics that are treated to beflame-resistant as well as flame-resistant fabrics made from inherentlyflame-resistant fibers. The former types of fabrics are not themselvesflame-resistant, but are made flame-resistant by applying to the fabrica chemical composition that renders the fabric resistant to flame. Thesetypes of fabrics are susceptible to losing their flame-resistance withrepeated laundering because the flame-resistant composition tends towash out. In contrast, inherently flame-resistant fabrics do not sufferfrom this drawback because they are made from fibers that are themselvesflame-resistant. The use of flame resistant clothing provides thermalprotection at the exposure area. The level of protection typically restsin the fabric weight and composition. After the source of the ignitionis removed, flame resistant garments will self-extinguish, limiting thebody burn percentage.

Various types of inherently flame-resistant (FR) fibers have beendeveloped, including modacrylic fibers (e.g., modacrylic fibers soldunder the PROTEX name from Kaneka Corporation of Osaka, Japan), aramidfibers (e.g., meta-aramid fibers sold under the NOMEX name andpara-aramid fibers sold under the KEVLAR name, both from E.I. Du Pont deNemours and Company of Wilmington, Del.), FR rayon fibers, oxidizedpolyacrylonitrile fibers, and others. It is common to blend one or moretypes of FR staple fibers with one or more other types of non-FR staplefibers to produce a fiber blend from which yarn is spun, the yarn thenbeing knitted or woven into fabrics for various applications. In such afiber blend, the FR fibers render the blend flame-resistant even thoughsome fibers in the blend may themselves be non-FR fibers, because whenthe FR fibers combust they release non-combustible gases that tend todisplace oxygen and thereby extinguish any flame.

For example, US 2005/0025963 discloses an intimate blend of staplefibers having 10 to 75 parts by weight of at least one aramid fiber, 15to 85 parts by weight of at least one modacrylic fiber, and 5 to 30parts by weight of at least one polyamide fiber. Another blend of staplefibers is disclosed in US 2004/0192134, including at least about 60percent FR fibers (modacrylic and/or aramid) and up to 40 percentsynthetic or natural non-FR fibers such as cotton or wool. U.S. Pat. No.6,787,228 discloses a yarn formed of a blend of fibers including atleast about 70 percent modacrylic fibers combined with at least about 3percent high-performance, high-energy-absorptive fibers such as aramid.

ASTM F1930-99 is a full-scale mannequin test designed to test fabrics incompleted garment form in a simulated flash fire. A mannequin, with upto 122 heat sensors spaced around its body, is dressed in the testgarment, and then exposed to a flash fire for a pre-determined length oftime. Tests are usually conducted at heat energies of 1.8-2 cal/cm²sec,and for durations of 2.5 to 5.0 seconds for single layer garments.Results are reported in percentage of body burn. For consistency in dataand accuracy of comparison, the test method defines a standard garmentsize and configuration that must be used on each test.

In addition to the above-noted performance specifications of fabrics,other properties are also important if a fabric is to be practical andcommercially viable, particularly for clothing. For instance, the fabricshould be durable under repeated industrial launderings and should havegood abrasion-resistance. Furthermore, the fabric should be comfortableto wear. Unfortunately, many of the FR blends are not comfortable undertypical environmental conditions. In such cases, wearers tend to be lesslikely to be compliant and thereby decreasing the probability that thewearer will continue to use the garment as intended. Thus, it isbeneficial if an FR fabric exhibits good moisture management properties,i.e., ability to wick away sweat and dry quickly so that the wearer doesnot become overheated or chilled, and/or the fabric does not irritatethe wearer's skin.

There exists a need for a fiber blend that is not only fire-resistantbut also provides superior moisture management properties and strengthproperties to ensure wearer compliance. The fiber blends, fabrics, andgarments of the present invention are directed toward these, as well asother, important ends.

SUMMARY OF THE INVENTION

The invention relates generally to fiber blends and to fabrics andgarments comprising the fiber blends that achieve a balance of highthermal properties and moisture management properties to provide bothprotection and comfort to the wearer.

Accordingly, in one embodiment, the invention is directed to fiberblends, comprising:

about 30-70%, by weight, based on the total weight of the fiber blend,of a hydrophobic fiber component comprising at least one polymerselected from the group consisting of modacrylic, fluoropolymer,polybenzimidazole (PBI), and copolymers thereof, and combinationsthereof;

about 15-45%, by weight, based on the total weight of the fiber blend,of a hydrophilic fiber component comprising at least one polymerselected from the group consisting of cellulose, cellulose derivatives,wool, and copolymers thereof, and combinations thereof;

about 10-30%, by weight, based on the total weight of the fiber blend,of at least one structural fiber component comprising at least onepolymer selected from the group consisting of aramid fiber, melaminefiber, nylon fiber, structural carbon fiber, and combinations thereof,wherein said aramid polymer is present at a level of at least about 10%,by weight, based on the total weight of the fiber blend; and

optionally, about 0.1-3% by weight, based on the total weight of thefiber blend, of at least one antistatic fiber.

In other embodiments, the invention is directed to yarns comprising thefiber blends described herein.

In other embodiments, the invention is directed to fabrics comprisingthe fiber blends described herein.

In yet other embodiments, the invention is directed to garments,especially outerwear, comprising the fabric formed from the fiber blendsdescribed herein.

DETAILED DESCRIPTION OF THE INVENTION

As employed above and throughout the disclosure, the following terms,unless otherwise indicated, shall be understood to have the followingmeanings.

As used herein, the singular forms “a,” “an,” and “the” include theplural reference unless the context clearly indicates otherwise.

As used herein, the term “about,” when referring to a measurable valuesuch as an amount, a temporal duration, and the like, is meant toencompass variations of ±20%, preferably ±10%, more preferably ±5%, evenmore preferably ±1%, and yet even more preferably ±0.1% from thespecified value, as such variations are appropriate to perform thedisclosed methods.

As used herein with reference to fabric, the term “formed substantiallyof” means that the fabric includes at least 50% by weight, based on thetotal weight of the fabric, preferably at least 75% by weight, based onthe total weight of the fabric, and more preferably at least 95% byweight, based on the total weight of the fabric of a specific fiberblend or yarn composition.

As used herein, the term “modacrylic fiber” refers to a acrylicsynthetic fiber made from a polymer comprising primarily residues ofacrylonitrile, especially polymers that have between 35 to 85%acrylonitrile units, and which may be modified by other monomers.Modacrylic fibers are spun from an extensive range of copolymers ofacrylonitrile. The modacrylic fiber may contain the residues of othermonomers, including vinyl monomer, especially halogen-containing vinylmonomers, such as but not limited to vinyl chloride, vinylidenechloride, vinyl bromide, vinylidene bromide, and the like. The types ofmodacrylic fibers that can be produced within this broad category arecapable of wide variation in properties, depending on their composition.Some examples of commonly available modacrylics are PROTEX™, KANEKALON™,and KANECARON™ by Kaneka Corporation. Modacrylic fibers have excellentfire retardancy performance combined with non-melt, non-drip andself-extinguishing properties. These are critically important attributesin many working environments. If sufficiently high temperatures arereached on exposure to fire or explosion, a garment made with theinventive fiber blends of the invention will carbonize by forming aprotective charred barrier. This prevents propagation of flames, therebyprotecting the wearer from severe burn injuries. Modacrylics have a highso-called LOI value as compared with other fibers. The LOI representsthe minimum oxygen concentration of an O₂/N₂ mix required to sustaincombustion of a material. The LOI is determined by the ASTM Test D2862-77. Modacrylics have an LOI value preferably between about 28 and33 while conventional polyesters have a much lower value of about 20 to22.

As used herein, the term “fluoropolymer” refers to a fluorocarbon-basedpolymer with at least one, but preferably multiple, strongcarbon-fluorine bonds, including, but not limited to,polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), orfluorinated ethylene-propylene (FEP).

As used herein, the term “aramid fiber” refers to a manufactured fiberin which the fiber-forming substance is a long-chain synthetic polyamidein which at least 85% of the amide linkages, (—CO—NH—), are attacheddirectly to two aromatic rings, including, but not limited to,para-aramid (p-aramid) and meta-aramid (m-aramid). Examples ofpara-aramids include, but are not limited to, (poly(p-phenyleneterephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company),TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company. KEVLAR is apara-aramid fiber having a very high tenacity of between 28 and 32grams/denier and outstanding heat resistance. Examples of meta-aramidsinclude, but are not limited to, (poly(m-phenylene isophthalamide), suchas NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (TeijinTwaron BV). Preferably, the structural fiber is p-aramid, microdenierp-aramid. Such structural fibers feature excellent thermal stability andare virtually non-flammable. These fibers have a very high resistance toheat and are resistant to melting, dripping and burning at a temperatureof at least 700° F. Moreover, their LOI value is preferably in the rangeof between about 28 and about 30.

As used herein, the term “melamine fiber” is a manufactured fiber inwhich the fiber-forming substance is a synthetic polymer composed of atleast 50% by weight of a crosslinked non-thermoplastic melamine polymerof melamine units joined by methylene and dimethylene ether linkages. Inthe polymerization reaction, methylol derivatives of melamine react witheach other to form a three-dimensional structure. This structure is thebasis for the fiber's heat stability, solvent resistance, and flameresistance.

As used herein, the term “antistatic fiber” refers to a fiber, whenincorporated into a fabric or other material, eliminates or reducesstatic electricity. Suitable fibers include, but are not limited to,metal fibers (steel, copper or other metal), metal-plated polymericfibers, and polymeric fibers incorporating carbon black on the surfaceand/or in the interior of the fiber, such as those described in U.S.Pat. No. 3,803,453, U.S. Pat. No. 4,035,441, U.S. Pat. No. 4,107,129,and the like. Antistatic carbon fiber is a preferred antistatic fiber.One example of such conductive fiber is NEGASTAT® produced by E.I. duPont de Nemours and Company, a carbon fiber comprising a carbon core ofconductive carbon surrounded by non-conductive polymer cover, eithernylon or polyester. Another example is RESISTAT® made ShakespeareConductive Fibers LLC, a fiber where the fine carbon particles areembossed on the surface of a nylon filament. The yarns of both suchfibers are available in a denier of at least 40. By way of example, asteel wire is available under the names BEKINOX and BEKITEX from BekaertS. A. in a diameter as small as 0.035 millimeter. Another antistaticfiber is the product X-static made by Noble Fiber Technologies, a nylonfiber coated with a metal (silver) layer. The X-static fibers may beblended with other fibers, such as modacrylics, in the process of yarnspinning.

As used herein, the term “structural carbon fiber” refers to fibers ofabout 0.005-0.010 mm in diameter and formed primarily of carbon atoms.The carbon atoms are bonded together in microscopic crystals that aremore or less aligned parallel to the long axis of the fiber. Each carbonfilament is produced from a precursor polymer. Common precursor polymersinclude commonly rayon, polyacrylonitrile (PAN), and petroleum pitch.For synthetic polymers such as rayon or PAN, the precursor is first spuninto filaments, using chemical and mechanical processes to initiallyalign the polymer atoms in a way to enhance the final physicalproperties of the completed carbon fiber. After drawing or spinning, thepolymer fibers are then heated to drive off non-carbon atoms(carbonization), producing the final carbon fiber. Suitable structuralfibers are available from Zoltek, SGL Carbon, Fortafil, Sumitomo, andKureha Corporation.

As used herein, the term “basis weight” refers to a measure of theweight of a fabric per unit area. Typical units include ounces persquare yard and grams per square centimeter.

As used herein, the term “garment” refers to any article of clothing orclothing accessory worn by a person, including, but not limited toshirt, pants, underwear, outer wear, footwear, headwear, swimwear,belts, gloves, headbands, and wristbands.

As used herein, the term “linen” (when not in relation to thehydrophilic fiber) refers to any article used to cover a worker orseating equipment used by workers, including, but not limited to sheets,blankets, upholstery covering, vehicle upholstery covering, and mattresscovering.

As used herein, the term “intimate blend,” when used in conjunction witha yarn, refers to a statistically random mixture of the staple fibercomponents in the yarn.

Accordingly, in one embodiment, the invention is directed to fiberblends, comprising:

about 30-70%, by weight, based on the total weight of the fiber blend,of a hydrophobic fiber component comprising at least one polymerselected from the group consisting of modacrylic, fluoropolymer,polybenzimidazole (PBI), and copolymers thereof, and combinationsthereof;

about 15-45%, by weight, based on the total weight of the fiber blend,of a hydrophilic fiber component comprising at least one polymerselected from the group consisting of cellulose, cellulose derivatives,wool, and copolymers thereof, and combinations thereof;

about 10-30%, by weight, based on the total weight of the fiber blend,of at least one structural fiber component comprising at least onepolymer selected from the group consisting of aramid fiber, melaminefiber, nylon fiber, structural carbon fiber, and combinations thereof;wherein said aramid fiber is present at a level of at least about 10%,by weight, based on the total weight of the fiber blend; and

optionally, about 0.1-3% by weight, based on the total weight of thefiber blend, of at least one antistatic fiber.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric provides protectionagainst second and third degree burns on less than about 35% of thewearer, when tested in accordance with the American Society for Testingand Materials Standard Test ASTM F 1930-2000. In preferred embodiments,fabric provides protection against second and third degree burns on lessthan about 25% of the wearer, when tested in accordance with theAmerican Society for Testing and Materials Standard Test ASTM F1930-2000. In more preferred embodiments, fabric provides protectionagainst second and third degree burns on less than about 15% of thewearer, when tested in accordance with the American Society for Testingand Materials Standard Test ASTM F 1930-2000.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a char lengthless than about 5 inches, preferably less than about 4 inches, whentested in accordance with the American Society for Testing and MaterialsStandard Test ASTM 6413.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a water vaportransmission of at least about 1100, when tested in accordance with theAmerican Society for Testing and Materials Standard Test ASTM E96 forWater Vapor Transmission, and a vertical wicking of at least about 6cm/5 minutes, when tested in accordance with Natick Internal Method No.4.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a wet tearvalue of at least equal to or greater than a corresponding dry tearvalue, when tested in accordance with the American Society for Testingand Materials Standard Test ASTM D 1424 (condition 1 dry; condition 2wet).

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a wet abrasionresistance of greater than about 4000 random abrasion cycles with a 9KPa load, and greater than about 5,000 dry random abrasion cycles with a9 KPa load using wet/dry 600 grit ultrafine sandpaper to simulate fieldusage, when tested in accordance with American Society for Testing andMaterials Standard Test ASTM D 4966 Abrasion Resistance of TextileFabrics—Martindale Abrasion Test Method.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a heat andthermal shrinkage resistance value of less than about 5%, when tested inaccordance with the National Fire Prevention Association NFPA 1971 and athermal protective performance value of at least about 5, preferably atleast about 5.7 (initial) and at least about 6.7 (after 3× washing),when tested in accordance with the National Fire Prevention AssociationNFPA 1971 (without spacer).

The hydrophobic fiber component of the fiber blend of the invention ispresent at a level of about 30-70%, by weight, based on the total weightof the fiber blend, and comprises at least one polymer selected from thegroup consisting of modacrylic, fluoropolymer, polybenzimidazole (MI),and copolymers thereof, and combinations thereof. In certain embodimentsof the fiber blend, the hydrophobic fiber component is present at about40-60%, by weight, based on the total weight of the fiber blend. Incertain other embodiments, the hydrophobic fiber component is present atabout 40-50%, by weight, based on the total weight of the fiber blend.In certain embodiments of the fiber blend, the hydrophobic fibercomponent is modacrylic or copolymer thereof. In other embodiments, thefluoropolymer is selected from the group consisting ofpolytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA),fluorinated ethylene-propylene (FEP), and mixtures thereof.

The hydrophilic fiber component of the fiber blend of the invention ispresent at a level of about 15-45%, by weight, based on the total weightof the fiber blend, and comprises at least one polymer selected from thegroup consisting of cellulose, cellulose derivatives (such as cotton,viscose, linen, rayon, fire-resistant rayon, or a combination thereof),wool, and copolymers thereof, and combinations thereof. In certainembodiments of the fiber blend, the hydrophilic fiber component ispresent at about 25-40%, by weight, based on the total weight of thefiber blend. In certain other embodiments, the hydrophilic fibercomponent is present at about 25-35%, by weight, based on the totalweight of the fiber blend. In other embodiments, the cellulosederivative is cotton, viscose, linen, rayon, or a combination thereof. Apreferred hydrophilic fiber component is cotton or fire-resistant rayon,or a combination thereof.

The structural component of the fiber blend of the invention is presentat a level of about 10-30%, by weight, based on the total weight of thefiber blend. The structural fiber component comprises at least onepolymer selected from the group consisting of aramid fiber, melaminefiber, nylon fiber, structural carbon fiber, and combinations thereof;wherein said aramid fiber is present at a level of at least about 10%,by weight, based on the total weight of the fiber blend. In certainembodiments of the fiber blend, the structural component is present atabout 20-30%, by weight, based on the total weight of the fiber blend.In certain other embodiments, the structural component is present atabout 25-30%, by weight, based on the total weight of the fiber blend.In other embodiments, the structural component is aramid fiber, such asm-aramid polymer fiber or p-aramid polymer fiber. In certainembodiments, the aramid fiber is present at a level of about 27-30%, byweight, based on the total weight of the fiber blend. In otherembodiments, the structural component is a combination of nylon fiberand aramid fiber, particularly p-aramid fiber. In certain otherembodiments, the structural component is a combination of nylon fiberand aramid fiber, particularly p-aramid fiber, where both components arepreferably present at a level of about 10%, by weight, based on thetotal weight of the fiber blend.

In certain embodiments of the fiber blend, an optional antistatic fiberis present at a level of about 0.1-3%, by weight, based on the totalweight of the fiber blend. In certain embodiments, the antistatic fiberis an antistatic carbon fiber.

In certain embodiments of the fiber blend,

the hydrophobic fiber component is modacrylic or a copolymer thereof;

the hydrophilic fiber component is cellulose or a cellulose derivative,or a combinations thereof; and

the structural fiber component is aramid fiber, nylon fiber, or acombination thereof.

In certain embodiments, the fiber blend is:

about 30-41%, by weight, based on the total weight of the fiber blend,of modacrylic and copolymers thereof;

about 30-41%, by weight, based on the total weight of the fiber blend,of cotton;

about 27-30%, by weight, based on the total weight of the fiber blend,of para-aramid fiber; and

about 2%, by weight, based on the total weight of the fiber blend, ofantistatic carbon fiber.

In certain embodiments, the fiber blend is:

about 50%, by weight, based on the total weight of the fiber blend, ofmodacrylic and copolymers thereof;

about 30%, by weight, based on the total weight of the fiber blend, ofcotton;

about 10%, by weight, based on the total weight of the fiber blend, ofnylon fiber; and

about 10%, by weight, based on the total weight of the fiber blend, ofpara-aramid fiber.

In another aspect, the invention is directed to yarns comprising thevarious fiber blends described herein, wherein said hydrophobic fibercomponent, said hydrophilic fiber component, said structural fibercomponent, and said optional antistatic fiber are intimately blended.

In another aspect, the invention is directed to fabrics formed from theyarns comprising the various blends described herein. The fabrics may beeither woven or knitted. In certain embodiments, the fabric has a basisweight of less than about 8.0 ounces/square yard (OPSY). In certainother embodiments, the fabric has a basis weight of less than about 6.0ounces/square yard (OPSY).

In some embodiments, the fabric may be formed into a garment. In certainembodiments, the fabric forms at least one outer portion of the garmentbecause of the protection it provides. The fabric is useful in garmentssuch as outwear, including, but not limited to coats, coveralls,overalls, shirts, and pants, and is particularly useful in firefighterturnout coats. In other embodiments, the fabric is formed into agarment, such as an undershirt, in a single tubular design to eliminateor reduce the number of seams and failure points.

In other embodiments, linen may be formed from the fabric of theinvention.

The present invention is further defined in the following Examples, inwhich all parts and percentages are by weight, unless otherwise stated.It should be understood that these examples, while indicating preferredembodiments of the invention, are given by way of illustration only.From the above discussion and these examples, one skilled in the art canascertain the essential characteristics of this invention, and withoutdeparting from the spirit and scope thereof, can make various changesand modifications of the invention to adapt it to various usages andconditions.

EXAMPLES Test Methods

The following test methods were used in the examples, unless otherwisenoted.

Heat and Thermal Shrinkage Resistance

This test determines the performance of fabrics when exposed to heat inan oven at 500° F. Observations of ignition, melting, dripping, orseparation are recorded and reported for each specimen. The percentchange in the width and length direction of the specimen is calculated.Results are recorded and reported as the average of three specimens.

Specimen marking and measurements are conducted in accordance with theprocedure specified in AATCC 135 Dimensional Change in Automatic HomeLaundering of Woven and Knit Fabrics. The specimen is suspended by metalhooks at the top and centered in the oven so that the entire specimen isnot less than 50 mm from any oven surface or other specimen, and air isparallel to the plane of the material. The specimen, mounted asspecified, shall be exposed in the test oven for 5 minutes at 500° F.

Flame Resistance of Textiles (Vertical) (ASTM D6413)

This test method determines the response of textiles to a standardignition source, deriving measurement values for after-flame time,afterglow time, and char length. The vertical flame resistance, asdetermined by this test method, only relates to a specified flameexposure and application time. This test method maintains the specimenin a static, draft-free, vertical position and does not involve movementexcept that resulting from the exposure. Test Method D6413 has beenadopted from Federal Test Standard No. 191A method 5903.1, which hasbeen used for many years in acceptance testing.

Samples cut from fabric to be tested are mounted in a frame that hangsvertically from inside the flame chamber. A controlled flame is exposedto the sample for a specified period of time. After-flame time, thelength of time the material continues to burn after removal of theburner, and after-glow time, the length of time the material glows afterthe flame extinguishes, are both recorded. Finally, the specimen is tornby use of weights and the char length, the distance from the edge of thefabric that was exposed to the flame to the end of the area affected bythe flame, is measured.

Natick Internal Method No. 4 (Drying Time Test Method)

Drying Time Test Method:

-   1. Fabric samples and blotting paper should be conditioned at    65+/−2% relative humidity and 21+/−1° C. (70+/−2° F.) for a minimum    of 4 hours before testing.-   2. Test three specimens from each sample. Each specimen consists of    a 2″×2″ piece cut wearing gloves. The long dimension should be cut    parallel to warp direction. Mark each specimen for identification as    a part of the sample set.-   3. Weigh the conditioned sample using a laboratory balance, accurate    to 0.1 g.-   4. Place 100 ml of distilled or reverse osmosis water into a 250 ml    beaker.-   5. Submerge one specimen in the beaker for 30 minutes. Make certain    that the specimen is completely submerged under the water to insure    complete wetting.-   6. Remove the specimen and sandwich it between two pieces of unused    blotter paper and pass it through the wringer. Leave the piece    sandwiched in the wet blotter paper. Repeat this process for the    remaining two specimens of the same sample.-   7. Weigh the blotted specimens one at a time.-   8. Record the weight as wet weight.-   9. Hang each sample separately to dry in a location that is in    conditions 65+/−2% relative humidity and 21+/−1° C. (70+/−2° F.).-   10. Weigh the samples t the nearest 0.1 g every 5 minutes recording    each weight, until completely dry.-   11. Repeat until all the specimens return to their original dry    weight. At this time, the overall drying time is calculated by    averaging the dry time of all three specimens.    Natick Internal Method No. 4 (Vertical Wicking Test)

A 500 ml Erlenmeyer flasks are filled with 200 ml colored water. 6 inchby 1 inch strip are cut from the fabrics to be tested. The top edge ofstrip is pierced with a long, straight pen. The strip is suspended frompin, in flask filled with 200 ml colored water. At standard intervals,the strip is removed from the flask and water level on the strip ismeasured and recorded.

AATCC MM TS-05 Gravimetric Drying Test Modified—Advanced Fabric DryingTime Test Method

Apparatus and Reagents

Analytical balances accurate to 0.0001 gram. Each bank of 4 balances isinterfaced with a computer that utilizes Labview data acquisitionsoftware for collecting test data Built-in draft shield on the balanceis used to minimize drafts, with only the top open to allow for drying.Vertical specimen stand is 3 inches wide and 6 inches tall.

Sampling and Specimens

For a typical test four 2.5×2.5 inch square specimens are used. Two ofthe specimens are the “control” (reference) fabric and two are from the“test” fabric of interest. More specimens can be used to increasetesting accuracy.

Conditioning

Samples are conditioned in the conditioning room at temperature of 70°F. and 55% relative humidity for at least 4 hours prior to test.

Procedures

Option B: Saturated. (note: This is essentially the Natick samplepreparation protocol)

-   1. Weigh the conditioned sample using a laboratory balance, accurate    to 0.0001 g.-   2. Place 10 mL of distilled water into a 25 ml beaker.-   3. Submerge one specimen in the beaker for 5-10 minutes. Make    certain that the specimen is completely submerged under the water to    insure complete wetting.-   4. Remove specimen from the beaker and sandwich it between two    pieced of unused AATCC blotter paper and pass it through the    wringer. Leave the piece sandwiched in the wet blotters. Repeat this    process for the remaining specimens of the same sample.-   5. Tare the vertical specimen stand on the balance position to be    used for that specimen.-   6. Mount the blotted specimen on the vertical stand and then place    it on the balance. Record the wet weight of the blotted specimen.-   7. Start the test by initiating data acquisition on the LabView    software. Weight readings are automatically recorded every 15    seconds by the computer.

The test is complete once the specimen weight has reached a designatedstopping moisture level vs. the dry conditioned weight. The stoppingmoisture level is typically 1% to 2.5% for cotton blend & cotton fabricsand 0.5% for polyester. The test is ended by stopping data acquisitionin LabView.

Calculation and Interpretation

Total drying time is the time it takes the specimen to reach thestopping weight.

Total water release rate (“WRR,” g/min) is calculated as follows:Total WRR=(wet specimen weight−ending specimen weight)/(total dryingtime)

ΔWRR, total (%) is calculated from the respective total WRR values asfollows:ΔWRR_(total)=100×(WRR_(test)−WRR_(control))/WRR_(control)

“Comfort Zone” drying time (minutes) is the time it takes the specimen'smoisture content to decrease from 15% to 0.5% (polyester) or 20% to1-1.5% (cotton).

“Comfort Zone” WRR (g/min) is calculated as follows:Active WRR=(wet specimen weight−ending specimen weight)/(“active” dryingtime)

ΔWRR (Comfort Zone) is calculated in the same manner as for ΔWRR(total)except using test and control WRR (Comfort Zone) values.

Moisture Vapor Transmission Test

ASTM E96 is used to measure moisture vapor transmission. A 4″×4″ fabricspecimen is prepared. A cup is filled with distilled water leaving asmall gap (0.75″ to 0.25″) of air space between the specimen and thewater. The cup is then sealed to prevent vapor loss except through thetest sample. An initial weight is taken of the apparatus and thenperiodically weighed over time until results become linear.

Example 1

The Air Force tiger stripe print base fabric is twill fabric withdiagonal weave (7.6 oz./sq. yd.) prepared from yarn of an intimate fiberblend of 50% Protex® M modacrylic fiber/30% Pima cotton/10% nylon/10%Twaron® para-aramid.

Heat and Thermal Shrinkage Resistance

Six fabric specimens (3 samples as received; 3 samples after three washcycles) were tested in accordance with NFPA 1971 (which is equivalent tothe standards set forth in NFPA 2112 and NFPA 1975) to measure heat andthermal shrinkage resistance, carried out at 500° F. for a test exposuretime of 5 minutes.

Results:

All specimens were not charred after exposure to heat.

As received:

-   -   % loss of length (2.5, 2.5, 2.5)    -   % loss of width (2.5, 2.5, 2.5)

After 3× washes

-   -   % loss of length (2.0, 2.0, 2.0)    -   % loss of width (2.0, 2.0, 2.0)        Flame Resistance of Textiles (Vertical)

Five fabric specimens were tested, as received, in accordance with ASTMD6413 to measure flame resistance. The test results are shown in thetable below:

After-Flame After-Glow Melting Drip Char Length (seconds) (seconds)(seconds) (mm) Length Direction Sample 1 0.0 4.0 0.0 11062 Sample 2 0.06.0 0.0 10567 Sample 3 0.0 4.0 0.0 8277 Sample 4 0.0 6.0 0.0 12971Sample 5 0.0 6.0 0.0 10682 Average 0.0 5.2 0.0 106.471.8 Width DirectionSample 1 0.0 5.06.0 0.0 10177 Sample 2 0.0 4.05.0 0.0 9181 Sample 3 0.07.05.0 0.0 9781 Sample 4 0.0 5.04.0 0.0 9563 Sample 5 0.0 6.05.0 0.011382 Average 0.0 5.45.0 0.0 99.476.8After 25 Washing

Melting After- Drip After-Flame Glow (sec- Char Length (seconds)(seconds) onds) (mm) Length Direction Sample 1 5.0 5.0 0.0 85 Sample 26.0 5.0 0.0 99 Sample 3 5.0 5.0 0.0 112 Sample 4 4.0 7.0 0.0 110 Sample5 4.0 6.0 0.0 82 Average 4.8 5.6 0.0 97.6 Width Direction Sample 1 5.06.0 0.0 82 Sample 2 3.0 5.0 0.0 102 Sample 3 6.0 5.0 0.0 110 Sample 45.0 4.0 0.0 80 Sample 5 5.0 5.0 0.0 97 Average 4.8 5.0 0.0 94.2 ASTMF1506 Requirements 2.0 seconds None 152 mm (maximum) (maximum)

Example 2

The Air Force tiger stripe print base fabric, a twill fabric withdiagonal weave (7.58 oz./sq. yd.), was prepared from yarn of an intimatefiber blend of 50% Protex® C modacrylic fiber/30% Pima cotton/10%nylon/10% Twaron® para-aramid.

Heat and Thermal Shrinkage Resistance

Six fabric specimens (3 samples as received; 3 samples after three washcycles) were tested in accordance with NFPA 1971 to measure heat andthermal shrinkage resistance, carried out at 500° F. for a test exposuretime of 5 minutes.

Results:

All specimens were not charred after exposure to heat.

As received:

-   -   % loss of length (2.5, 2.5, 2.5)    -   % loss of width (2.5, 2.5, 2.5)

After 3× washes

-   -   % loss of length (2.0, 2.0, 2.0)    -   % loss of width (2.0, 2.0, 2.0)        Air Permeability

The sample was tested for air permeability in accordance with ASTM-D737.The resulting measured air permeability is 20.1 foot³/minute/foot².

Water Vapor Transmission

The sample was tested for water vapor transmission in accordance withASTM E96 Procedure B (water method, 74.5° F., 48% relative humidity; airgap 11/16″). The resulting transmission rate measured was 1255.0 g/m²/24hour average.

Moisture Wicking

The results of the 1″ strip moisture wicking at 70° F., 65% relativehumidity are shown in the table below.

Height of Wicking (cm) Time (seconds) Length Width 30 3.8 3.0 60 5.0 4.390 6.0 5.2 120 6.7 5.9 150 7.3 6.6 180 7.9 7.1 210 8.3 7.5 240 8.9 7.9270 9.2 8.3 300 9.5 8.6Drying Test

Three 2″×2″ samples were cut from the test fabrics and conditioned untila constant mass was reached. The conditioning cabinet used was an ESPECwith forced air circulation (0.4 m/s average) and set at constanttemperature of 70° F.+/−1° F. and humidity 65%+/−3%. Samples were wettedwith deionized water to a water pick-up of approximately 65%. Sampleswere then weighted every 5 minutes under constant conditions until theoriginal mass was reached to approximately 1%. Baseline evaporation ofstanding water in the cabinet was measured to be 0.043 g/5 minutes onaverage. The results are shown in the following table.

Time (minutes) Wet Pick-up (%) 0 45.3 5 40.79 10 34.74 15 29.81 20 23.7425 18.68 30 13.69 35 8.75 40 4.69 45 2.33 50 1.33 55 0.71 60 0.00Thermal and Water Vapor Resistance

Thermal and water vapor resistance under steady conditions guarded hotplate test in accordance with ISO 11092 were measured. The intrinsicinsulation measured was 0.13

Example 3

A rip stop woven fabric (5.75 oz./sq. yd.) was prepared from a yarn ofan intimate fiber blend of 41% modacrylic/30% cotton/27% para-aramid/2%antistatic carbon fiber. The woven fabric was tested and the results areshown in the following table.

Test Description Test Method Target Minimum Maximum Results Weight(oz/yd²) ASTM D3776 5.75 −5% +5% 5.84 Breaking strength ASTM D5034 150 ×110 100 × 60 152 × 115 Tear strength ASTM D1424 8 × 8  6 × 6 7.4 × 7.6(Elmendorf) Air permeability ASTM D737 35 25 50 37.6 Initialflammability ASTM D6413-99 (Wales/Courses) Char length 5.0″ maximum 4 53.6 × 3.6 (inches) After flame 2.0 seconds 0 2 0 (seconds) maximum Afterglow 8.0 seconds 5 8 4.7 × 5.2 (seconds) maximum Melt/drip None NoneNone Thermal protective NFPA 1971 7.4 (initial) 7.4 performance (nospacers) Initial Flame resistance ASTM F 1930- <35% 35% 34.69%(Instrumented 2000 mannequin test) (% burn - 2^(nd) and 4 seconds flame3^(rd) degree) exposure

Example 4

A woven twill fabric (7.6 oz./sq. yd.) was prepared from a yarn of anintimate fiber blend of 50% modacrylic/30% cotton/10% nylon/10%para-aramid. The woven twill fabric was tested and the results are shownin the following table.

Test Description Test Method Target Minimum Maximum Results Weight(oz/yd²) ASTM D3776 7.5 −5% +5% 7.58 Breaking strength ASTM D5034 115 ×75 100 × 60 115.7 × 75   Tear strength ASTM D1424  3 × 5  6 × 6 2.96 ×4.64 (Elmendorf) Air permeability ASTM D737 20 15 25 20.1 Initialflammability ASTM D6413-99 (Wales/Courses) Char length 5.0″ maximum 4 54.18 × 3.9  (inches) After flame 2.0 seconds 0 2 0 (seconds) maximumAfter glow 8.0 seconds 5 8 5.2 × 5.4 (seconds) maximum Melt/drip NoneNone None Flammability after ASTM D6413-99 25 washes/dry after 25 homecleaning laundering w/d (Wales/Courses) cycles Char length 4.0″ maximum4 5 3.8 × 3.7 (inches) After flame 2.0 seconds 0 2 0 (seconds) maximumAfter glow 8.0 seconds 5 8 4.8 × 4.8 (seconds) maximum Melt/drip NoneNone None Heat and thermal NFPA 1971.2000 Pass Pass shrinkage resistanceed Thermal protective NFPA 1971 performance (no spacers) Initial 5.7 5.7After 3x washing 6.7 6.7 Clo Factor ISO 11092 (under 0.13 0.13 steadystate conditions) Flame resistance ASTM F 1930- 15% 25% 19.30%(Instrumented 2000 mannequin test) (% burn - 2^(nd) and 4 seconds flame3^(rd) degree) exposure

Comparative Example 5

Navy colored, knitted fabric formed from a fiber blend of 83%modacrylic/15% cotton/2% TWARON™ para-aramid was tested in accordancewith NFPA 1975 (equivalent to NFPA 1971 and NFPA 2112) (heat and thermalshrinkage resistance for station/work uniforms for fire and emergencyservices) (test temperature: 500° F.; test exposure time: 5 minutes).Three samples were tested. Immediately after exposure specified, thespecimens were removed and examined for evidence of charring,embrittlement, ignition (i.e., initiation of combustion, as set forth inASTM D6413 flame resistance of textiles), melting and dripping orseparation. Knit fabrics were pulled to original dimensions and allowedto relax for five minutes prior to measurement to determine pass orfail.

Results:

All three samples failed, when evaluated after heat at 500° F. Allsamples exhibited smoldering, i.e., the combustion of a solid materialwithout accompaniment of flame but generally with the production ofsmoke (as set forth in ASTM D6413 flame resistance of textiles). Allsamples remained charred and brittle after exposure to heat. The samplescould not be exercised and re-measured for shrinkage.

Comparative Example 6

Green colored, knitted fabric formed from a fiber blend of 80% PROTEX™modacrylic/15% cotton/5% TWARON™ para-aramid was tested in accordancewith NFPA 1975 (heat and thermal shrinkage resistance for station/workuniforms for fire and emergency services) (test temperature: 500° F.;test exposure time: 5 minutes). Three samples were tested. Immediatelyafter exposure specified, the specimens were removed and examined forevidence of charring, embrittlement, ignition (i.e., initiation ofcombustion, as set forth in ASTM D6413 flame resistance of textiles),melting and dripping or separation. Knit fabrics were pulled to originaldimensions and allowed to relax for five minutes prior to measurement todetermine pass or fail.

Results:

All three samples failed, when evaluated after heat at 500° F. Allsamples exhibited smoldering, i.e., the combustion of a solid materialwithout accompaniment of flame but generally with the production ofsmoke (as set forth in ASTM D6413 flame resistance of textiles). Allsamples remained charred and brittle after exposure to heat. The samplescould not be exercised and re-measured for shrinkage.

Comparative Example 7

Green colored, knitted fabric formed from a fiber blend of 75% PROTEX C™modacrylic/15% Pima cotton/10% BASOFIL™ melamine fiber was tested inaccordance with NFPA 1975 (heat and thermal shrinkage resistance forstation/work uniforms for fire and emergency services) (testtemperature: 500° F.; test exposure time: 5 minutes). Three samples weretested. Immediately after exposure specified, the specimens were removedand examined for evidence of charring, embrittlement, ignition (i.e.,initiation of combustion, as set forth in ASTM D6413 flame resistance oftextiles), melting and dripping or separation. Knit fabrics were pulledto original dimensions and allowed to relax for five minutes prior tomeasurement to determine pass or fail.

Results:

All three samples failed, when evaluated after heat at 500° F. Allsamples exhibited smoldering, i.e., the combustion of a solid materialwithout accompaniment of flame but generally with the production ofsmoke (as set forth in ASTM D6413 flame resistance of textiles). Allsamples remained charred and brittle after exposure to heat. The samplescould not be exercised and re-measured for shrinkage.

Comparative Example 8

Green colored, knitted fabric formed from a fiber blend of 80% PROTEX C™modacrylic/15% Pima cotton/5% BASOFIL™ melamine fiber was tested inaccordance with NFPA 1975 (heat and thermal shrinkage resistance forstation/work uniforms for fire and emergency services) (testtemperature: 500° F.; test exposure time: 5 minutes). Three samples weretested. Immediately after exposure specified, the specimens were removedand examined for evidence of charring, embrittlement, ignition (i.e.,initiation of combustion, as set forth in ASTM D6413 flame resistance oftextiles), melting and dripping or separation. Knit fabrics were pulledto original dimensions and allowed to relax for five minutes prior tomeasurement to determine pass or fail.

Results:

All three samples failed, when evaluated after heat at 500° F. Allsamples exhibited smoldering, i.e., the combustion of a solid materialwithout accompaniment of flame but generally with the production ofsmoke (as set forth in ASTM D6413 flame resistance of textiles). Allsamples remained charred and brittle after exposure to heat. The samplescould not be exercised and re-measured for shrinkage.

Comparative Example 9

Green colored, knitted fabric formed from a fiber blend of 85% PROTEX C™modacrylic/15% cotton was tested in accordance with NFPA 1975 (heat andthermal shrinkage resistance for station/work uniforms for fire andemergency services) (test temperature: 500° F.; test exposure time: 5minutes). Three samples were tested. Immediately after exposurespecified, the specimens were removed and examined for evidence ofcharring, embrittlement, ignition (i.e., initiation of combustion, asset forth in ASTM D6413 flame resistance of textiles), melting anddripping or separation. Knit fabrics were pulled to original dimensionsand allowed to relax for five minutes prior to measurement to determinepass or fail.

Results:

All three samples failed, when evaluated after heat at 500° F. Allsamples exhibited smoldering, i.e., the combustion of a solid materialwithout accompaniment of flame but generally with the production ofsmoke (as set forth in ASTM D6413 flame resistance of textiles). Allsamples remained charred and brittle after exposure to heat. The samplescould not be exercised and re-measured for shrinkage.

Comparative Example 10

Knitted fabric formed from a fiber blend of 75% PROTEX™ modacrylic/25%cotton was tested in accordance with NFPA 1971-07 (heat and thermalshrinkage resistance test; modified to use 7 inch specimens with 5 inchbenchmarks). Three samples were tested as received. Immediately afterexposure specified, the specimens were removed and examined for evidenceof melting, dripping or separation, or ignition (i.e., initiation ofcombustion, as set forth in ASTM D6413 flame resistance of textiles).

Results:

There was no melting, dripping, separation, or ignition of any of thesamples. The samples exhibited severe color change. The dimensionstability measurements were difficult to obtain due to the materialgathering into small wrinkles and folds.

Sample 1 Sample 2 Sample 3 Average Pass/fail Length −40.0 −35.0 −35.0−36.7 Fail Width −67.0 −67.6 −65.0 −66.5 Fail

Example 11

When two examples of the invention were compared with a comparativeblend outside of the invention, the benefits of faster overall dryingare clear, when tested in accordance with AATCC MM TS-05 GravimetricDrying Test Modified. The results are shown in the table below.

Dry time Total dry in WRR in time comfort WRR comfort Wet (total - zone(20- (Total - zone (20- Weight Pick- 1.5% 1.5% 1.5% 1.5% Fiber BlendContent (oz/yd²) Up moisture) moisture) moisture) moisture) DRIFIRE ®Example A 7.8 31.6 57.5 41.9 0.54 0.47 50% modacrylic/30% cotton/10%nylon/10% para-aramid DRIFIRE Example B 5.9 30.3% 63.1 48.3 0.47 0.4040% modacrylic/31% cotton/ 27% para-aramid/2% antistat CompetitiveExample C 6.0 31.0% 66.6 54.5 0.46 0.36 65% FR rayon/ 25%para-aramid/10% nylon

Even a much heavier weight DRIFIRE® Example A (7.8 osy fabric) canabsorb the same percentage of weight of water (2.45 oz of water) as theComparative Example C 6.0 osy (1.82 oz of water) yet still dry faster(DRIFIRE Example A dried in 57.5 minutes versus 66.6 minutes for theComparative Example C), which results in a higher overall water releaserate. When these same fabrics are tested from a more realistic 20% byweight to 1.5% remaining moisture the blends of the invention providethe wearers with improved comfort and ability to keep the body cool bymoving heat-containing sweat away from the skin, into the fabric, anddrying more rapidly than the comparative blend.

Example 12

When two examples of the invention were compared with a comparativeblend outside of the invention, the benefits of improved dry and wetabrasion are apparent, when tested in accordance with ASTM D 4966. Theresults are shown in the table below.

Number of Number of Wet Abrasion Abrasion cycles Dry Abrasion Abrasioncycles Resistance to develop a Resistance to develop a hole (ASTM D holein the Fiber Blend Content (ASTM D 4966) in the fabric 4966) fabric 7.8osy DRIFIRE ® 0.00% 14000+ 0.76%  9000-10000 Example A 50%modacrylic/30% cotton/10% nylon/ 10% para-aramid 5.9 osy DRIFIRE 0.33%11000-12000 0.66% 5000-6000 Example B 40% modacrylic/31% cotton/27%para- aramid/2% antistat 6.0 osy Comparative 0.64% 4000-5000 1.90%3000-4000 Example C 65% FR rayon/ 25% para-aramid/10% nylon

Abrasion of the fabric can lead to a reduction weight, thickness, andeventually the failure of the fabric with a hole forming which exposesthe wearer directly to an electric arc or fire threat. Having fabricsmade of improved abrasion resistance yarns can result in longer lastingprotective garments. These improved blends provide improved moisturemanagement (water release rate) without sacrificing dry and wet abrasionresistance.

Example 13

A khaki-colored plain woven fabric (5.75 oz./sq. yd.) was prepared froma yarn of an intimate fiber blend of 40% modacrylic/31% cotton/27%para-aramid/2% antistat. The plain woven fabric was tested and theresults are shown in the following table.

Test Description Test Method Results Weight (oz/yd²) ASTM D3776 5.82Tensile ASTM D5034 Warp 142.2 lbs. average Filling 117.9 lbs averageTear strength ASTM D1424 7.20 lbs. average (Elmendorf) 4.74 lbs. averageSeam slippage ASTM D434 Warp direction: 45.9 lbs. average seam breakFilling direction: 50.4 lbs. average seam break Thermal protective NFPA2112 Heat transfer rate with spacer (as received): 12.1 cal/cm²/secperformance Heat transfer rate after 3 × machine washing with spacer:12.4 cal/cm²/sec Heat transfer rate without spacer (as received): 13.4cal/cm²/sec Heat transfer rate after 3 × machine washing without spacer:12.5 cal/cm²/sec Heat and thermal Test temperature: Dimensional change(as received): wales = +2%; courses = −0.2% shrinkage resistance 500° F.(pass) Test exposure Dimensional change (after 3 × washings)): wales =+1.9%; time: 5 minutes courses = +0.6% (pass) Flame resistance of ASTMD6413 See below textiles (vertical) Char length ASTM D6413 As received:length: 113.3 mm; width: 102.9 (inches) 100x per NFPA2112: length: 125.4mm; width: 106.2 After flame ASTM D6413 As received: length: 0 seconds;width: 0 seconds (seconds) 100x per NFPA2112: length: 0 seconds; width:0 seconds After glow ASTM D6413 As received: length: 6.9 seconds; width:6.8 seconds (seconds) 100x per NFPA2112: length: 10.3 seconds; width:11.1 seconds Melt/drip ASTM D6413 As received: none 100x per NFPA2112:length: none

When ranges are used herein for physical properties, such as molecularweight, or chemical properties, such as chemical formulae, allcombinations, and subcombinations of ranges specific embodiments thereinare intended to be included.

The disclosures of each patent, patent application, and publicationcited or described in this document are hereby incorporated herein byreference, in their entirety.

Those skilled in the art will appreciate that numerous changes andmodifications can be made to the preferred embodiments of the inventionand that such changes and modifications can be made without departingfrom the spirit of the invention. It is, therefore, intended that theappended claims cover all such equivalent variations as fall within thetrue spirit and scope of the invention.

What is claimed is:
 1. A fiber blend, comprising: about 30-70%, byweight, based on the total weight of the fiber blend, of a hydrophobicfiber component comprising at least one polymer selected from the groupconsisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), andcopolymers thereof, and combinations thereof; about 15-45%, by weight,based on the total weight of the fiber blend, of a hydrophilic fibercomponent comprising at least one polymer selected from the groupconsisting of cellulose, cellulose derivatives, wool, and copolymersthereof, and combinations thereof; about 10-30%, by weight, based on thetotal weight of the fiber blend, of at least one structural fibercomponent comprising at least one polymer selected from the groupconsisting of aramid fiber, melamine fiber, nylon fiber, structuralcarbon fiber, and combinations thereof; wherein said aramid fiber ispresent at a level of at least about 10%, by weight, based on the totalweight of the fiber blend; and about 0.1-3% by weight, based on thetotal weight of the fiber blend, of at least one antistatic fiber.
 2. Afiber blend of claim 1, wherein, when said fiber blend is formed into afabric formed substantially of said fiber blend, said fabric providesprotection against second and third degree burns on less than about 35%of the wearer, when tested in accordance with the American Society forTesting and Materials Standard Test ASTM F 1930-2000.
 3. A fiber blendof claim 1, wherein, when said fiber blend is formed into a fabricformed substantially of said fiber blend, said fabric has a char lengthless than about 5 inches, when tested in accordance with the AmericanSociety for Testing and Materials Standard Test ASTM
 6413. 4. A fiberblend of claim 1, wherein, when said fiber blend is formed into a fabricformed substantially of said fiber blend, said fabric has a water vaportransmission of at least about 1100, when tested in accordance with theAmerican Society for Testing and Materials Standard Test ASTM E96 forWater Vapor Transmission, and a vertical wicking of at least about 6cm/5 minutes, when tested in accordance with Natick Internal Method No.4.
 5. A fiber blend of claim 1, wherein, when said fiber blend is formedinto a fabric formed substantially of said fiber blend, said fabric hasa wet tear value of at least equal to or greater than a correspondingdry tear value, when tested in accordance with the American Society forTesting and Materials Standard Test ASTM D 1424 (condition 1 dry;condition 2 wet).
 6. A fiber blend of claim 1, wherein, when said fiberblend is formed into a fabric formed substantially of said fiber blend,said fabric has a wet abrasion resistance of greater than about 4000random abrasion cycles with a 9 KPa load, and greater than about 5,000dry random abrasion cycles with a 9 KPa load using wet/dry 600 gritultrafine sandpaper to simulate field usage, when tested in accordancewith American Society for Testing and Materials Standard Test ASTM D4966 Abrasion Resistance of Textile Fabrics—Martindale Abrasion TestMethod.
 7. A fiber blend of claim 1, wherein, when said fiber blend isformed into a fabric formed substantially of said fiber blend, saidfabric has a heat and thermal shrinkage resistance value of less thanabout 5%, when tested in accordance with the National Fire PreventionAssociation NFPA 1971 and a thermal protective performance value of atleast about 5, when tested in accordance with the National FirePrevention Association NFPA 1971 (without spacer).
 8. A fiber blend ofclaim 1, wherein said hydrophobic fiber component is present at about40-60%, by weight, based on the total weight of the fiber blend.
 9. Afiber blend of claim 1, wherein said hydrophobic fiber component ispresent at about 40-50%, by weight, based on the total weight of thefiber blend.
 10. A fiber blend of claim 1, wherein said hydrophilicfiber component is present at about 25-35%, by weight, based on thetotal weight of the fiber blend.
 11. A fiber blend of claim 1, whereinsaid hydrophilic fiber component is present at about 25-30%, by weight,based on the total weight of the fiber blend.
 12. A fiber blend of claim1, wherein said structural fiber component is present at about 20-30%,by weight, based on the total weight of the fiber blend.
 13. A fiberblend of claim 1, wherein said structural fiber component is present atabout 25-30%, by weight, based on the total weight of the fiber blend.14. A fiber blend of claim 1, wherein said hydrophobic fiber componentis modacrylic or copolymer thereof.
 15. A fiber blend of claim 1,wherein said fluoropolymer is polytetrafluoroethylene (PTFE),perfluoroalkoxy polymer (PFA), or fluorinated ethylene-propylene (FEP).16. A fiber blend of claim 1, wherein said cellulose derivative iscotton, viscose, linen, rayon, or a combination thereof.
 17. A fiberblend of claim 1, wherein said hydrophilic fiber component is cotton.18. A fiber blend of claim 1, wherein said structural fiber component isaramid fiber.
 19. A fiber blend of claim 18, wherein said aramid fiberis m-aramid polymer or p-aramid polymer.
 20. A fiber blend of claim 1,wherein said hydrophobic fiber component is modacrylic or a copolymerthereof; wherein said hydrophilic fiber component is cellulose or acellulose derivative, or a combinations thereof; and wherein saidstructural fiber component is aramid fiber, nylon fiber, or acombination thereof.
 21. A fiber blend, comprising: about 30-41%, byweight, based on the total weight of the fiber blend, of modacrylic andcopolymers thereof; about 30-41%, by weight, based on the total weightof the fiber blend, of cotton; about 27-30%, by weight, based on thetotal weight of the fiber blend, of para-aramid fiber; and about 2%, byweight, based on the total weight of the fiber blend, of an antistaticcarbon fiber.
 22. A yarn comprising the fiber blend of claim 1, whereinsaid hydrophobic fiber component, said hydrophilic fiber component, saidstructural fiber component, and said antistatic fiber are intimatelyblended.
 23. A fabric comprising the yarn of claim
 22. 24. A fabric ofclaim 23, wherein said fabric is formed substantially of said fiberblend and wherein said fabric provides protection against second andthird degree burns on less than about 35% of the wearer, when tested inaccordance with the American Society for Testing and Materials StandardTest ASTM F 1930-2000.
 25. A fabric of claim 23, wherein said fabric isformed substantially of said fiber blend and wherein said fabric has achar length less than about 5 inches, when tested in accordance with theAmerican Society for Testing and Materials Standard Test ASTM
 6413. 26.A fabric of claim 23, wherein said fabric has a water vapor transmissionof at least about 1100, when tested in accordance with the AmericanSociety for Testing and Materials Standard Test ASTM E96 for Water VaporTransmission, and a vertical wicking of at least about 6 cm/5 minutes,when tested in accordance with Natick Internal Method No.
 4. 27. Afabric of claim 23, wherein said fabric is formed substantially of saidfiber blend and wherein said fabric has a wet tear value of at leastequal to or greater than a corresponding dry tear value, when tested inaccordance with the American Society for Testing and Materials StandardTest ASTM D 1424 (condition 1 dry; condition 2 wet).
 28. A fabric ofclaim 23, wherein said fabric is formed substantially of said fiberblend and wherein said fabric has a wet abrasion resistance of greaterthan about 4000 random abrasion cycles with a 9 KPa load, and greaterthan about 5,000 dry random abrasion cycles with a 9 KPa load usingwet/dry 600 grit ultrafine sandpaper to simulate field usage, whentested in accordance with American Society for Testing and MaterialsStandard Test ASTM D 4966 Abrasion Resistance of TextileFabrics—Martindale Abrasion Test Method.
 29. A fabric of claim 23,wherein said fabric has a heat and thermal shrinkage resistance value ofless than about 5%, when tested in accordance with the National FirePrevention Association NFPA 1971 and a thermal protective performancevalue of at least about 5, when tested in accordance with the NationalFire Prevention Association NFPA 1971 (without spacer).
 30. A fabric ofclaim 23, wherein said fabric has a basis weight of less than about 8.0ounces/square yard (OPSY).
 31. A fabric of claim 23, wherein said fabrichas a basis weight of less than about 6.0 ounces/square yard (OPSY). 32.A fabric of claim 23, wherein said fabric is woven.
 33. A fabric ofclaim 23, wherein said fabric is knitted.
 34. A garment comprising thefabric of claim
 23. 35. A garment of claim 34, wherein said fabric formsat least one outer portion of said garment.
 36. A garment of claim 34,wherein said garment is outerwear.
 37. A garment of claim 36, whereinsaid outerwear is a coat, coverall, overall, shirt, or pants.
 38. Agarment of claim 37, wherein said outerwear is a firefighter turnoutcoat.